Method for producing a plant life enhancing product

ABSTRACT

A method for producing a plant life enhancing product is described. The method includes: (i) anaerobically digesting agricultural residue to produce an anaerobically activated organic residue and an ammonia-enriched water; (ii) aerobically digesting the ammonia-enriched water to produce an aerobically activated organic residue; and (iii) blending the anaerobically activated organic residue with the aerobically activated organic residue to produce the plant life enhancing product.

RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 61/727,097, filed on Nov. 15, 2012, entitled “Novel Systems And Methods For Treatment Of Gaseous And Solid Byproducts Of Wastewater Treatment”, which is related to U.S. patent application Ser. No. 13/750,989, filed Jan. 25, 2013, entitled “Novel Systems And Methods For Converting Gaseous Byproducts Of Wastewater Treatment Into Energy”, which claims priority to and is a divisional of U.S. patent application Ser. No. 12/577,129 filed on Oct. 9, 2009, which is now U.S. Pat. No. 8,382,983, issued Feb. 26, 2013, all of which are incorporated herein for all purposes.

FIELD

The present teachings relate generally to wastewater treatment and byproducts thereof. More particularly, the present teachings relate to novel systems, methods and compositions involving plant life enhancing products produced from wastewater treatment and/or byproducts thereof.

BACKGROUND

Large volumes of water are used in the operation of dairies and farms, where crops and animals are raised. The resulting wastewater is mainly organic in nature and nutrient rich. Moreover, a significant amount of organics and/or nutrients are in the form of complex molecules that are not readily absorbed by plants and animals. To keep up with a diminishing water supply in some regions and lower water and energy costs, attempted wastewater treatment solutions are passive in nature and offer no effective solution to recover the nutrients. The attempted solutions also fail to provide nutrients in a form that may be used by the plants and animals.

SUMMARY

In view of the foregoing, the present teachings offer novel systems and methods for wastewater treatment and byproducts that provide plant and animal life enhancing products. In one aspect, the present teachings provide a system for producing plant life enhancing product. The system includes: (i) an anaerobic tank for anaerobically digesting agricultural residue to produce an anaerobically activated organic residue and an ammonia-enriched water; (ii) a solids removal sub-assembly for separating the ammonia-enriched water from the anaerobically activated organic residue to produce a substantially ammonia-free anaerobically activated organic residue; (iii) an aerobic tank for aerobically digesting the ammonia-enriched water to produce an aerobically activated organic residue; and (iv) a blending unit for blending the anaerobically activated organic residue with aerobically activated organic residue to produce the plant life enhancing product.

In another aspect, the present teachings provide a method for producing a plant life enhancing product. The method includes: (i) anaerobically digesting agricultural residue to produce an anaerobically activated organic residue and an ammonia-enriched water; (ii) aerobically digesting the ammonia-enriched water to produce an aerobically activated organic residue; and (iii) blending the anaerobically activated organic residue with the aerobically activated organic residue to produce the plant life enhancing product.

In yet another aspect, the present teachings provide a plant life enhancing composition. The plant life enhancing component includes: (i) an effective amount of a bioavailable component that is available for immediate absorption by a plant; (ii) an effective amount of a precursor component, which has a more complex molecular structure than the bioavailable component and over a duration transforms into the bioavailable component; and (iii) an effective amount of a catalyst that facilitates transformation of the precursor component to the bioavailable component.

In yet another aspect, the present teachings provide another plant life enhancing composition comprising: (i) an effective amount of a dormant component, which includes an output of aerobic digestion; (ii) an effective amount of a decomposed dormant component, which includes an output of anaerobic digestion; and (iii) an effective amount of a catalyst that facilitates transformation of the dormant component to the decomposed dormant component.

Conventional wastewater treatments typically release noxious gases into the environment, contributing to the greenhouse effect. The present teachings provide novel systems and methods for capturing those gases, converting those gases into useful energy, and doing so preferably in a substantially closed system. It is an objective, among many, of the present teachings to convert otherwise harmful byproducts to useful energy, preferably using some of the treated water resulting from wastewater treatment.

The approach adopted by the present teachings recognizes, among other things, that the concept of biochemical oxygen demand (“BOD”) drives various steps of wastewater treatment. BOD is a well-known parameter, which indicates the amount of oxygen needed to biologically stabilize the organic matter present. According to preferred embodiments of the present teachings, efforts to effectively control BOD levels in various stages of wastewater treatment rely upon more than gravity and time. This allows the present teachings to offer active treatment of wastewater, as opposed to prior art's passive treatment, which relies only upon gravity and time.

Organic matter commonly present in wastewater uses oxygen for various reasons and as a result, depletes soluble oxygen. A requisite high level of dissolved oxygen, however, is desirable during certain stages of treatment to grow microorganisms to consume organic matter present in wastewater treatment. Conventional methods only in a single discrete step grow microorganisms by introducing oxygen to replenish the depleted levels of oxygen in wastewater. This step provides oxygen to initially promote growth of naturally occurring microorganisms to large numbers so that they consume almost all of the organic matter and oxygen in wastewater. Conventional methods introduce oxygen by implementing passive means, i.e., requiring a large space-consuming tank to expose a greater surface area to the atmosphere for long periods of time.

The present teachings recognize the need to maximize use of high-pressure air diffusion in multiple steps to actively increase the amount of dissolved oxygen in wastewater as well as creating an active environment for naturally occurring and custom introduced bacteria to grow by increasing the surface-area-to-volume ratio in specific reactors. In preferred embodiments of the present teachings, this process of actively introducing oxygen and increasing surface-area-to-volume ratio begins early, during a solids-removal stage, and well before microorganisms growth is encouraged in conventional methods.

When sufficient amount of microorganisms die in an oxygen- and nutrient-poor environment, dead organisms undergo decay, raising levels of ammonia, nitrate, and nitrite through a process known as “nitrification.” Conventional treatment discharges the wastewater with a high concentration of nitrogen and phosphorous to the environment. Reverse osmosis and ion exchange are known to remove nitrogen and phosphorous, but are not deemed commercially viable and are therefore not integrated into conventional wastewater treatment methods.

Discharge of nutrient-rich effluent is known to be injurious to life. Nitrates are carcinogenic and direct discharge of wastewater with nitrates may contaminate drinking water aquifers. The present teachings recognize this and prevents such contamination by effectively removing nitrogen and phosphorous from wastewater before discharge.

Preferred embodiments of the present teachings effectively treat wastewater by driving down BOD, maintaining the level of dissolved oxygen, lowering the solid content, and controlling the nutrient level in wastewater at various stages. By way of example, in one stage, the present teachings drive down BOD and solid content in wastewater by actively focusing on the removal of BOD-contributing solids.

As another example, during the process of removing solids, the present teachings also focus on improving the growth regime for naturally occurring and genetically engineered bacteria. Preferred embodiments of the present teachings use high-pressure air diffusion to substantially maintain or increase the level of dissolved oxygen in wastewater. As a result, according to preferred embodiments of the present teachings, microorganism growth is encouraged well before they are employed to remove organic matter.

As yet another example, directly after removal of organic matter by microorganism consumption, preferred embodiments treat wastewater by creating anaerobic conditions to achieve complete microorganism die off and lower solid content or reduce BOD in wastewater. Next, the wastewater is treated to remove solids and further reduce BOD in an aerobic environment, which replenishes the dissolved oxygen levels.

As yet another example, preferred embodiments of the present teachings, while actively removing BOD-contributing solids, dead microorganisms, nutrients, algae, and other solids, maintain the level of dissolved oxygen in wastewater to prevent an increase of BOD and solid content by reversible reaction. It is important to note that prior art fails to recognize drawbacks of reversible reactions, which increase BOD, let alone offer provisions to prevent increase of BOD.

As yet another example, preferred embodiments of the present teachings drive down the nutrients in wastewater by actively focusing on the removal of all forms of nitrogen and phosphates by effectively cultivating specific biological processes that utilize nutrients available for their own growth. The teachings further reduce the nutrient load by actively removing any biological matter remaining in the effluent.

As yet another example, the present teachings offer provisions to capture methane and other components of biogas to convert methane into electricity and to convert other components of biogas and byproducts of the electricity conversion process to chemical species, which promote growth or production of useful products. In preferred embodiments of the present teachings, a portion of treated water resulting from wastewater treatment is used in conjunction with biogas and gases produced during anaerobic and aerobic digestion, respectively, in a useful manner as opposed to releasing such gases to the atmosphere, as conventional processes do.

In yet another aspect, the present teachings provide a method for removing methane from biogas. The method includes: (i) receiving biogas including methane and other components into a first tank; (ii) receiving water into the first tank; (iii) contacting the biogas with the water inside the first tank; (iv) dispensing methane gas from an outlet of the first tank; and (v) producing from the tank an effluent stream that includes other components of the biogas. The step of contacting may include passing bubbles of biogas through the water. Water may be obtained from any source of purified water. Preferably, however, water is obtained from a wastewater treatment facility.

In one embodiment of the present teachings, the inventive methods may further include a step of carrying out digestion of water enriched with organic matter in a second tank to produce the biogas. The second tank may be different from the first tank. The organic matter in the water may be between about 0.5% by volume and about 25% by volume.

In preferred embodiments of the present teachings, inventive methods include a step of sending the effluent stream from the tank to a diffused air flotation (“DAF”) tank that is designed to effect removal of solids.

Inventive methods may further include a step of sending the methane gas to an electrical generator that is designed to burn methane gas and produce electrical energy. Preferably, the electrical generator produces exhaust gases which include at least one of CO₂ gas, SO_(x) gas, and NO_(x) gas, and are treated in a third tank by contacting the exhaust gases with water to remove at least one of CO₂ gas, SO_(x) gas, and NO_(x) gas from the third tank and produce water having dissolved therein at least one of CO₂ gas, SO_(x) gas, and NO_(x) gas. More preferably, the water having dissolved therein at least one of CO₂ gas, SO_(x) gas, and NO_(x) gas is delivered to an algal pond. The algal pond may be a high rate algal pond (“HRAP”).

In yet another aspect, the present teachings provide a method for removing byproduct gases after aerobic digestion. The method includes: (i) receiving into a first tank a gaseous mixture including at least one of ammonia gas and sulfur gas; (ii) receiving water into the first tank; (iii) contacting the gaseous mixture including at least one of the ammonia gas and the sulfur gas with the water inside the first tank to produce an effluent stream of water having dissolved therein the at least one of aqueous ammonia and sulfur and produce a residual gaseous mixture including at least one of ammonia gas and sulfur gas; (iv) dispensing residual gas including at least one of residual ammonia gas and residual sulfur gas; and (v) discharging the effluent stream including water which has dissolved therein the at least one of aqueous ammonia and sulfur gas. Residual gaseous mixture refers to the gas or gases that do not dissolve in water. The step of dispensing may include recirculating the residual gaseous mixture from outlet of the first tank to an inlet of the first tank. The step of contacting may include passing bubbles of the gaseous mixture through the water.

In yet another aspect, the present teachings provide a system for removing byproducts of anaerobic digestion. The system includes: (i) a first tank including: (a) a first inlet that is connected to receive byproduct gases of anaerobic digestion including at least one gas and methane, (b) a first outlet that provides methane gas as exhaust, (c) a second inlet that is connected to receive a stream of water, and (d) a second outlet that discharges an effluent water stream having dissolved therein the above-mentioned at least one gas into a tank designed for removing solids; and (ii) an electrical generator that is connected to the first outlet of the first tank; and wherein the first tank is designed to contact the stream of water with the byproduct gases of anaerobic digestion and produce the effluent stream of water. In preferred embodiments, the electrical generator produces electricity and a gas including at least one of CO₂ gas, SO_(x) gas, and NO_(x) gas.

In yet another aspect, the present teachings provide a system for wastewater treatment. The system includes: (i) a solids-removal subassembly designed to remove solids from wastewater and produce solids-depleted water; (ii) an assembly designed for processing organic material in the solids-depleted wastewater to produce treated water and the assembly connected to the solids-removal subassembly; (iii) a tank that has a first inlet, a first outlet, and a second outlet; and (iv) wherein the first inlet of the tank is designed to receive treated water, the first outlet is designed to discharge a first portion of treated water, the second outlet is designed to discharge a second portion of treated water, and the first portion of treated water is used for processing byproduct gases resulting from wastewater treatment. Preferably, the tank may be a holding tank that is located downstream from a nutrient-removal tank, which is designed to remove nutrients from wastewater. In alternative embodiments of the present teachings, the tank is a nutrient-removal tank designed to remove nutrients from wastewater

In yet another aspect, the present teachings provide a method of wastewater treatment. The method includes the steps of: (i) removing solids from wastewater to produce solids-depleted water; (ii) processing organic material in the solids-depleted wastewater to produce treated water; (iii) discharging a first portion of treated water and a second portion of treated water; and (iv) using the first portion of treated water to process byproduct gases resulting from wastewater treatment. In preferred embodiments, the present teachings provide the further step of removing nutrients from wastewater. The above-mentioned step of using may be carried out after removing nutrients.

The construction and method of operation of the teachings, however, together with additional objects and advantages thereof will be best understood from the following descriptions of specific embodiments when read in connection with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows an exemplar system for wastewater treatment, according to one present arrangement.

FIG. 1B shows an exemplar system, according to one embodiment of the present teachings, for separating methane gas from biogas that is produced after anaerobic digestion.

FIG. 1C shows an exemplar system, according to one present arrangement, for treating gas produced by aerobic and anaerobic digestion.

FIG. 2 shows details of a BCR design, according to one present arrangement, used in the system of FIG. 1A.

FIG. 3 shows an exemplar algal pond used in the system of FIG. 1A.

FIG. 4 shows a perspective view of the algal pond of FIG. 3.

FIG. 5 shows an exemplar system, according to one present arrangement, for converting methane gas into electricity.

FIG. 6 shows an exemplar system for converting solid byproducts of wastewater treatment into plant life enhancing product, e.g., fertilizer, pesticide, biocide, and/or agricultural feed, according to one present arrangement.

FIG. 7 shows an exemplar flow diagram, according to one present arrangement, for converting solid byproducts of wastewater treatment into plant life enhancing products (e.g., fertilizer, pesticide, biocide, and/or agricultural feed).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In the following description numerous specific details are set forth in order to provide a thorough understanding of the present teachings. It will be apparent, however, to one skilled in the art that the present teachings may be practiced without limitation to some or all of these specific details. In other instances, well known process steps have not been described in detail in order to not unnecessarily obscure the teachings.

FIG. 1A shows a system design 100, according to one embodiment of the present teachings, for active treatment of wastewater. System 100 includes an anaerobic tank 102, inside which anaerobic digestion of wastewater takes place. In other words, inside anaerobic tank 102, organic content in wastewater is broken down into simpler molecules, which may be further treated by other methods. A byproduct of anaerobic digestion, biogas 128, is collected at the top surface of anaerobic tank 102 (not shown to simplify illustration) and delivered to a system for treatment resulting in product that may be converted into clean energy (described below with reference to FIGS. 1B and 5).

System design 100 provides wastewater that has undergone anaerobic digestion to a series of active devices for removal of solid waste. These active devices include a solids separator 104, a DAF tank 106, and a first SRT 108, each of which facilitates removal of solid contaminants of different sizes and type. The relatively solid-free wastewater is then transported to a series of BCRs 110 and 112 to remove organic matter. For removal of solid sludge, if necessary, an aerobic sludge digester tank 114 is provided. Wastewater containing dead microorganisms from either BCR 112 or from aerobic sludge digester 114, if one is employed, is sent to a second SRT 116 for removal of solids, which include for the most part dead microorganisms. For further removal of dead organisms, the wastewater is treated in DAF tank 106 and from there sent to HRAP 118. HRAP 118 is provided to remove nutrients, such as nitrates, nitrites, and phosphorous from the wastewater. Next, wastewater is passed again through DAF tank 106 and through a third SRT 120 to specifically remove algae introduced into wastewater from HRAP 118. DAF tank 106 also serves to increase level of dissolved oxygen in wastewater. The nutrient-and-algae-depleted wastewater is optionally provided to a maturation pond 122 before discharging to the environment. In maturation pond 122, residual algae not removed in either DAF tank 106 or SRT 120 is removed and treated wastewater is exposed to elements of the natural environment. In preferred embodiments of the present teachings, a portion of the effluent stream flowing through line 125 from maturation pond 122 facilitates conversion of various byproducts of wastewater treatment (described below with reference to FIGS. 1B and 1C) to useful energy (described below with reference to FIG. 5) or useful downstream products (described below with reference to FIGS. 1B, 1C, and 5).

System 100 also includes various lines or connections between the different tanks to transport residual solids that are removed from the wastewater. According to FIG. 1A, one such line 124 is provided between DAF tank 106 and anaerobic tank 102 to transport those solids which are not removed after treatment in DAF tank 106 back to a subsystem for drying and pelletizing. Another line 127 is also provided to transport solids, which typically include dead microorganisms, from aerobic sludge digester 114 to a subsystem designed for drying and pelletizing. The resulting pellets are used for fertilizer, pesticide, and/or biocide (described below with reference to FIGS. 6 and 7). According to the embodiment shown in FIG. 1A, residual solids are not only transported from aerobic sludge digester 114, but are also transported to digester 114. Specifically, a line 128 is provided to transport residual solids from DAF tank 106 back to aerobic sludge digester 114.

In addition to conveying wastewater at different stages of treatment and conveying residual solids, various lines or connections between the different tanks of system 100 deliver biogas and gas to produce energy and other useful downstream products. By way of example, a gaseous mixture 128, which includes methane and other gases captured as byproducts of anaerobic digestion inside anaerobic tank 102, is transported to a tank 126 shown in FIG. 1B. In preferred embodiments of the present teachings, tank 126 is a scrubber designed to contact gaseous mixture 128 with liquid stream 125. As another example, a portion of effluent stream 125 from maturation pond 122 is used to contact gaseous mixture 142 of FIG. 1C. FIG. 1C, described in greater detail below, shows processing of the gas or gaseous mixture resulting from aerobic digestion.

From tank 126 of FIG. 1B, a line 130 is provided to DAF tank 106 (as shown in FIG. 1A) to deliver an effluent water stream having dissolved therein certain biogas components, such as ammonia, carbon dioxide, hydrogen, and sulfur, but not including methane, for further treatment. A detailed description of FIG. 1B explains how the effluent entering DAF tank 106 shown in FIG. 1A is produced.

In system 100, gas (which includes ammonia gas and sulfur gas) emanating from processing of organic matter inside BCR 110 (shown in FIG. 1A) is delivered via line 142 to a tank 140. Tank 140 is preferably a scrubber that is configured to contact a portion of treated water 125 (shown in FIGS. 1A and 1B), for example, with the gas generated inside BCR 110. In other embodiments of the present teachings, instead of using a portion of treated water stream 125, any water stream that is relatively pure may be used.

Solids separator 104 comes equipped with a screen designed to remove solids that do not settle out in anaerobic tank 102 or that are pulled into system 100 by the inlet pumps (not shown to simplify illustration of FIG. 1A). Solids in wastewater that pass through the screen are pressed between at least two belts, each of which is supported by turning rollers positioned throughout the press. The belts are permeable and allow wastewater to pass through, holding back heavy solids. Moving action of the belt and the splashing of wastewater, as it permeates the belt, also serve to introduce oxygen into wastewater. The resulting increased level of dissolved oxygen encourages growth of microorganisms, which remove organic matter in a subsequent step.

Depending on the screen size, solids separator 104 removes between about 75% and about 98% of solids removed from wastewater, which at this stage of treatment typically has a solid content that is between about 15% and about 30%. Eliminating these solids represents a significant amount of BOD removal. Solids removed by the press may be composted or otherwise removed from the premises for disposal. Solids separator 104 may be made from any rigid material, but is preferably made from stainless steel. Similarly, a range of suitable dimensions work well. In one preferred embodiment of the present teachings, system 100 uses a solids separator commercially available from Press Technologies of Wheat Ridge, Colo.

DAF tank 106 captures small particulate matter that is not removed by solids separator 104. To effect solid separation from wastewater, DAF tank 106, in accordance with one embodiment of the present teachings, uses a pored diffuser and a high-pressure pump that is preferably fitted with a venturi tube and is designed to introduce air bubbles inside wastewater. The pump draws in air, forcing air bubbles through the pored diffuser to form micro-air bubbles. The pored diffuser may be made from stone. Air is forced through the pored diffuser to produce a diffused air flow, preferably of about 40 cubic feet per minute. Air bubbles in their upward motion accumulate on the particulate matter and carry with them particulate matter to the top, where they are removed via skimmers.

Air bubbles inside DAF tank provide a large surface area to effectively dissolve oxygen and thereby raise the level of soluble oxygen in wastewater. As a result, air bubbles not only facilitate removal of solids, but also increase the level of dissolved oxygen in wastewater to promote microorganism growth for subsequent removal of organic matter. Thus, the present teachings promote conditions for effective removal of organic matter in early stages and well before such removal is the primary focus during subsequent treatment.

In preferred embodiments of the present teachings, DAF tank is commercially available from Martint Environmental of Lexington, S.C. By way of example, a DAF tank used in the present teachings is about 7 feet long, 3.5 feet wide, and 5 feet high. Hydraulic residence time in a DAF tank may be between about 1 and about 3 hours. Hydraulic residence time refers to the amount of time it takes for a single molecule of water to pass through the unit from the time it enters a tank, for example, to the time it leaves. DAF tank removes between about 85% and about 95% of the solids removed from wastewater, which at this point has a solid content that is between about 3% and about 6%.

Unlike conventional solid sedimentation in the prior art, the present teachings do not require solids to fully settle to the bottom of the SRT to be trapped there. SRT 108 effects separation of residual solids by actively increasing the hydraulic flow path and providing physical impediments to particles for permanently trapping them. Hydraulic flow path refers to a path that is traversed by wastewater. An increase in the hydraulic flow path allows for separating a greater amount of solids from wastewater.

SRT 108 is preferably large enough such that it takes wastewater being pumped in at 40 gallons per minute 100 minutes to fill it. U.S. Pat. No. 6,899,808, which is incorporated herein by reference for all purposes, describes preferred embodiments of the SRT used in the present teachings. Surface area inside SRT 108 is preferably between about 160 square feet and about 320 square feet. SRT removes between about 85% and about 90% of solids having particle sizes greater than 20 micrometers from wastewater, which at this point has a solid content of about 1%. During the solid removal process, SRT 108 effects diffused air flow to raise level of dissolved oxygen in wastewater and to clean the screens provided for solid removal. By reducing ROD level and solid content and raising level of dissolved oxygen in wastewater, the present teachings promote conditions for removal of organic matter in early stages and well before such removal is the primary focus during subsequent treatment.

FIG. 2 shows a cross-sectional view of a BCR 200 (e.g., BCRS 110 and 112), in accordance with one embodiment of the present teachings. BCR 200 includes a tank 202, which contains biological chips 214 and has an inlet 208 for providing wastewater (not shown to simplify illustration) for treatment. Tank 202 is equipped with a blower 204 which introduces air inside wastewater. Waste solids in wastewater form a layer 212 and are removed by a pump 210. Biological chips 214 and blower 204 serve to provide wastewater with very high dissolved oxygen concentration and a high surface-area-to-volume ratio to aid the metabolic growth rates of microorganisms (not shown in FIG. 2 to simplify illustration).

BCR is an aerobic treatment system that utilizes microorganisms attached to biologic chips to form a biological film or slime layer (typically ranging from 0.1 mm to 0.2 mm thick). Microorganisms in the outer part of slime layer degrade the organic material in wastewater. However, as the slime layer thickens, oxygen is unable to penetrate the biological chips and anaerobic organisms develop. Eventually the microorganisms near the surface lose their ability to cling to the biological chips, and a portion of the slime layer falls off.

In accordance with one embodiment of the present teachings, microorganisms inside a BCR include aerobic, anaerobic and facultative bacteria, fungi, and protozoa. BCR 110 is preferably designed to contain many different types of microorganisms, each of which is ideally suited to remove at least one type of organic matter from wastewater. By way of example, BCR 110 uses heterotrophic bacteria (e.g., Achromobacter, Alcaligenes, Arthrobacter, Cirtomonas, Flavobacterium, Pseudomonas, and Zoogloea) for removal of BOD. BOD is created by any matter containing a carbon molecule normally present in wastewater and that is generated from any one of human waste, food waste, animal waste, and plant waste.

Blower 204 is effective in providing oxygen to microorganisms in wastewater. Size of bubbles formed in wastewater from pumping air and the amount of air pumped dictate the amount of oxygen dissolved in wastewater. Those skilled in the art will recognize that small bubbles may be twice as efficient at transferring oxygen because they provide greater surface area of air per mass of air. Bubbles also mix wastewater inside the BCR to ensure that nutrients in wastewater are in constant contact with the bacteria that consumes them.

The presence of biological chips provides a high surface area inside the reactor to which the microorganisms may affix. By way of example, the ratio of surface area inside the BCR to volume of BCR is between about 32 square feet per cubic foot and about 130 square feet per cubic foot. Preferably, however, the ratio of surface area inside the BCR to volume of BCR is about 73.5 square feet per cubic feet. High surface area combined with high oxygen concentration aide the metabolic rates of microorganisms. The affixed microorganisms quickly remove all available food in the form of organic particulate matter (which contribute to BOD) from the reactor and leave a situation of high metabolic rates and low amounts of food (i.e., there is a low ratio of food to microorganism). Over a period of time, most solids in the reactors continue to be active and remove more BOD from the influent water. Eventually, as more and more of the food is depleted inside the reactor, the microorganisms die from starvation.

BCR 112 is preferably designed to contain at least one type of microorganism, which removes at least one type of organic matter that is particularly difficult to remove from the wastewater in BCR 110 or requires additional processing time, i.e., above and beyond the processing time in BCR 110. According to the present teachings, it is also possible to have additional BCRs, in addition to BCRs 110 and 112, to facilitate effective organic matter removal. By way of example, an initial step of nitrification is carried out in BCR 112 by autotropic bacteria Nitrosomonas, which converts ammonia to nitrite, despite the fact that some nitrifying bacteria exist in BCR 110. A third BCR (not shown in FIG. 1A to simplify illustration) may be used for a subsequent step of nitrification using autotropic bacteria Nitrobacter.

In preferred embodiments of the present teachings, BCRs 110 and 112 are about 7 feet long, 10.5 feet wide, and 8 inches in height. Temperature inside BCRs is preferably between about 15° C. and about 33° C., and the hydraulic residence time is preferably about 8 hours. According to one embodiment of the present teachings, BCRs are about 40% filled with small biorings, have 133 cubic feet per minute of diffused air flowing through it during operation, and use 6 ounces of defoaming agent per day. In cold climates, where heat dissipation is relatively high, it is preferable to keep substrate levels high to carry out nitrification effectively. The term “high substrate levels” means keeping a certain level of biological matter (sludge) inside the BCR to maintain its thermal mass and avoid wide temperature swings inside the BCR and/or also means keeping the bacteria count high to accommodate the greater die-off rate when temperatures drop.

The present teachings use of a BCR, individually or in combination with other BCRs, represent an active process because it is provides air and constantly places bacteria in contact with nutrients through circulation of wastewater to effectively encourage nutrient uptake. Furthermore, the surface area inside the BCR is also optimized for removal of organic waste.

Aerobic sludge digester 114 is one type of BCR, except that it is designed to remove sludge. In other words, digester 114 contains microorganisms that are known to consume, and therefore remove, sludge.

Although the BCRs and aerobic sludge digesters remove organic matter and lower the BOD, they leave wastewater rich with nitrates from the endogenous decay of microorganisms that have run out of food source. To this end, previously described DAF tank 106 and a second SRT, shown as SRT 116 in FIG. 1A, are used to remove dead microorganisms. To remove dead microorganisms, DAF tank 106 is provided with another chamber, separate from the chamber which is used to remove from wastewater solids that are not dead microorganisms. IIRAP 118 is used in system 100 to remove nutrients from wastewater.

FIG. 3 shows HRAP 300, according to one preferred embodiment of the present teachings. HRAP 300 includes a tank 302 containing algae 308. A spectrum of radiation 306 operates at wavelengths that range from about 10² nm and 10⁶ nm. This spectrum of radiation is preferably disposed at a location that is between about ⅓ and about ½ the depth of HRAP 300. At the bottom of tank 302, a solid waste layer 304 accumulates which may ultimately be removed. A hydraulic pump and a paddle (both not shown to simplify illustration) are preferably provided in HRAP 300 for stirring and aeration of wastewater. Aeration and stirring facilitates driving up the dissolved oxygen level in wastewater to promote algae growth. Tank 302 is preferably maintained at a temperature that is between about 21° C. and 35° C.

FIG. 4 shows a perspective view of HRAP 300, in accordance with one preferred embodiment of the present teachings. Inside HRAP 300 wastewater is preferably guided through a channel, which allows the water to traverse back and forth along a length of tank 302. The channel carves out a hydraulic path for wastewater and is preferably serpentine in shape.

HRAP may have any dimensions that effectively remove nutrients from wastewater. The present teachings recognize, however, that nutrient load and flow rate of wastewater drive HRAP dimensions. By way of example, HRAP has a length of about 24 feet, a width of about 77 feet, and a height of about 4 feet. IIRAP preferably provides a surface area that is between about 1000 square feet and about 50,000 square feet and, more preferably, about 1848 square feet for wastewater treatment. The channel length is preferably between about 200 feet and about 3000 feet. Inside the channel of HRAP, wastewater moves at a velocity of 10 inches per second and has a residence time of about 72 hours.

HRAP primarily uses algae to remove nitrates and phosphates from wastewater. Growth rate of algae is dictated by available oxygen, temperature, light, and nutrients. Conventional algal ponds are very shallow because they facilitate introduction of oxygen and penetration of light to promote algae growth. Unfortunately, for processing relatively large volumes of wastewater, conventional algal ponds are very large, i.e., they are typically measured in hectares.

The present teachings preferably use an HRAP, which is deeper and not so spread out. In preferred embodiments of the present teachings, it both aerates and stirs wastewater to effectively introduce oxygen. Furthermore, a radiation source inside the HRAP effectively facilitates penetration of light through greater depths of wastewater. As a result, HRAPs according to the present teachings may occupy as little as 160 square meters for 120-cubic-meters-per-day flow systems.

Preferably contemporaneous with above-described treatment of wastewater, the present teachings also treat byproducts resulting from wastewater treatment. To this end, FIG. 1B shows a system 140, according to one embodiment of the present teachings, for separating methane gas from other components of biogas that are produced after anaerobic digestion in wastewater. Although this system and other such systems which process byproducts of wastewater treatment may function either in a contemporaneous or non-contemporaneous manner relative to wastewater treatment, in preferred embodiments, inventive systems and methods process the byproducts in a contemporaneous manner to increase throughput and avoid byproduct build-up.

System 140 includes a tank 126, preferably a scrubber, for removal of methane 132 so that it may subsequently be used as energy source (described below with reference to FIG. 5). Tank 126 includes a first inlet for receiving a stream of water (e.g., a portion of treated water 125 from maturation pond 122 of FIG. 1A), a first outlet for dispensing an effluent water stream 130 having dissolved therein certain components of biogas, a second inlet for receiving biogas 128 produced after anaerobic digestion, and a second outlet for methane exhaust 132. As shown in FIG. 1A, methane, one component of biogas, is a residual gas as it is not soluble in water.

Tank 126 may receive a water stream from any source of water or pure water. In the interest of water conservation, the present teachings recognize that a portion of treated wastewater resulting from wastewater treatment may be used for processing byproducts of wastewater treatment.

Tank 126 preferably comes equipped with a bubbler 129 to produce bubbles. Specifically, bubbler 129 introduces biogas 128 inside a tank full of water in the form of micro-bubbles. The bubbles provide a large surface area between the biogas/water interface to facilitate dissolving certain soluble biogas components in water. Residual methane gas exits tank 126 and is further processed as described below in system 170 of FIG. 5.

FIG. 5 shows a system 170, according to one embodiment of the present teachings, for converting methane exhaust into electricity and for converting residual gases resulting from an electricity generator to a simpler, less complicated molecular form that may be used by HRAP 118 of FIG. 1A to foster growth of algae, which is useful for producing, among other things, biofuels. System 170 includes an electrical generator 150 and a tank 160, which is preferably a scrubber. Electrical generator 150 uses methane exhaust 132 (generated inside tank 126 of FIG. 1B) to generate electricity and a produce a gaseous mixture 152 (e.g., including at least one of CO₂, SO_(x), and NO_(x)), which are fed into a tank 160. According to FIG. 5, a portion of treated water 125 from maturation pond 122 of FIG. 1A enters tank 160 such that it contacts gaseous mixture 152 of tank 160. A bubbler 156, similar to bubbler 129 of FIG. 1B, ensures that the gaseous mixture in the form of micro bubbles contacts water to facilitate dissolving components of the gaseous mixture in water. As a result, a certain amount of the gaseous components of mixture 152 dissolves in the treated water to form water 162 that is enriched with aqueous components (i.e., predominantly at least one of CO₂, SO_(x), and NO_(x)). As shown in FIG. 5, this gas-enriched water stream 162 is advanced to HRAP 118 of FIG. 1A, where algae production is promoted by the dissolved gaseous components in water. The residual gases, which include remaining amounts of at least one of CO₂, SO_(x), and NO_(x) that did not dissolve in treated water, are recycled back to tank 160 via line 154 for further treatment. The goal of the recycling feature of FIG. 1B is to ultimately dissolve all of CO₂, SO_(x), and/or NO_(x) gases in water and advance these gases to HRAP 118 of FIG. 1A to promote algae growth.

FIG. 1C shows a system 180, according to one embodiment of the present teachings, for processing gas (i.e., predominantly ammonia gas and sulfur gas) produced by BCR 110 of FIG. 1A. According to this figure, gaseous byproducts resulting from aerobic digestion of wastewater that is carried out in BCR 110, are transported to a tank 140, preferably a scrubber, for processing. Like tank 160 of FIG. 5 and tank 126 of FIG. 1A, tank 140 of FIG. 1C comes equipped with bubbler 139, which introduces the gas produced in BCR 110 in the form of micro bubbles through the tank full of treated water to facilitate dissolving in water of those components of the gaseous byproducts that are soluble in water. Tank 160 includes a first inlet for receiving water and a first outlet for dispensing water, which is enriched with at least a soluble amount of gaseous components that dissolve. In preferred embodiments of the present teachings, the water is treated water 125 from maturation pond 122 of FIG. 1A. However, it is possible to so treat the gaseous byproducts with a water stream obtained from any source. Tank 140 has a second inlet for receiving gas from BCR 110 and a second outlet for dispensing the residual gas that does not dissolve in water.

An ammonia concentration sensor 182 is located downstream from tank 140 and is capable of controlling the flow of effluent stream from tank 140 to either HRAP 118 or back to BCR 110. To this end, ammonia sensor 182 is communicatively coupled to two different valve assemblies 184 and 186 via control lines 188 and 190, respectively. When ammonia concentration sensor 182 detects ammonia concentration in the effluent stream of tank 140 to be either equal to or greater than a predetermined concentration value, sensor 182 activates valve assembly 184 to convey an effluent stream of tank 140 to BCR 110 for further treatment. In the alternative, when sensor 182 detects ammonia concentration in the effluent stream to be less than the predetermined concentration value, sensor 182 activates valve assembly 186 to convey the effluent stream to HRAP 118. In preferred embodiments of the present teachings, the value of predetermined ammonia concentration lies in a range that is between about 0 ppm and about 10 ppm, depending primarily on the concentration of ammonia in a feed stream that is being reduced by oxidation, e.g., in the BCR reactor. An effluent stream with low ammonia concentration suggests nitrogen is present in the effluent stream in a less complex form which is useful for promoting algae growth in HRAP 118. In contrast, a high ammonia concentration suggests that the effluent stream does not have sufficient amount of nitrogen in simple form to facilitate algae growth in HRAP 118. Those skilled in the art will recognize that although system 180 is shown in connection with BCR 110, a similar system could be used to process the gas emanating in BCR 112 of FIG. 1A. Regardless of whether gas emanating from BCR 110 or BCR 112 is processed as described above, if the concentration of ammonia in the effluent stream of a scrubber, for example, is greater than or equal to a predetermined concentration value, then that effluent stream is sent hack to the BCR so that the dissolved aqueous ammonia in the effluent stream may be broken down to a simpler form which is ultimately useful to promote algae growth in HRAP 118.

Similar to ammonia gas, sulfur is another gaseous byproduct of aerobic digestion carried out in BCR 110 or BCR 112 of FIG. 1A. Instead of or in addition to using an ammonia concentration sensor, system 180 of FIG. 1C may include a sensor for detecting the concentration of sulfur gas (not shown to simplify illustration) if the presence of sulfur gas is expected or suspected as a byproduct of aerobic digestion. Those skilled in the art will recognize that the valve assemblies, similar to those shown in connection with the ammonia concentration sensor, may be used in conjunction with the sulfur concentration sensor. Because sulfur naturally dissipates faster relative to ammonia, it is not necessary in preferred embodiments of the present teachings to monitor the sulfur concentration in the same way as the ammonia concentration. In even more preferred embodiments of the present teachings, only the ammonia concentration is measured and so long as that concentration is less than a predetermined value, it is safe to assume that the sulfur concentration is also sufficiently low to advance the effluent stream from tank 140 to HRAP 118.

In preferred embodiments of the present teachings, electrical generator 150 is commercially available from General Electric, Inc.'s Jenbacher gas engine division located in Jenbach, Austria. However, other electrical generators, which use methane to generate electricity will work also.

In preferred embodiments of the present teachings, tank 126 (in system 140 of FIG. 1B), tank 140 (in system 180 of FIG. 1C), and tank 160 (system 170 of FIG. 5) are large enough to hold at least a volume of liquid that is between about 380 liters and about 38000 liters.

Wastewater treatment according to present teachings has many advantages over the conventional wastewater treatment technology. At a minimum, conventional wastewater treatment processes release noxious byproducts of anaerobic and aerobic digestion into the atmosphere, some of which are believed to contribute to the greenhouse effect. In sharp contrast, the present teachings offer novel systems and methods to process these byproducts to generate clean energy and promote production of useful downstream products. In preferred embodiments of the novel systems and methods of the present teachings, a portion of the treated wastewater is used to process the byproducts as mentioned above. It is counter to conventional wisdom that treated or purified water obtained from wastewater treatment should be used to treat environmentally harmful byproducts because after putting a substantial amount of energy in treating wastewater, conventional wastewater techniques teach away from wasting that energy by contaminating that treated water. As a result, conventional wastewater treatment processes fail to recognize, among other things, that a portion of the treated water may be used to convert byproducts of wastewater treatment into clean energy. The present teachings provide a substantially closed system that treats wastewater and recycles a portion of that treated wastewater to convert noxious byproducts of wastewater treatment into useful energy. By way of example, if the closed system is implemented on a farm, then the wastewater generated at the farm may be treated and at the same time be used to produce clean energy for the farm.

In other respects unrelated to treatment of byproducts, at a minimum, conventional wastewater treatment processes fail to recognize: (i) that decomposition of organic matter depletes soluble oxygen in wastewater constantly during various treatment steps; (ii) the need to substantially maintain the level of dissolved oxygen in wastewater at various stages is important for effective treatment; and (iii) that failure to substantially maintain level of dissolved oxygen and lower solid content through each stage of wastewater treatment causes a reversible reaction which reverses the treatment accomplished in previous treatment steps.

To this end, various steps in preferred embodiments of the present teachings recognize the need to drive down BOD, solid content, and nutrient level and maintain or increase level of dissolved oxygen in wastewater. In preferred embodiments of the present teachings, wastewater undergoes different types of treatment. By way of example, BOD-creating solids are removed first. Then, the bacteria consume the organic matter. Next, nutrients present in wastewater are removed. After performing a first type of treatment, however, the present teachings recognize the need to stabilize the wastewater before advancing it to a second type of treatment. Stabilizing involves preventing a meaningful change in certain important properties of wastewater, e.g., ROD level, dissolved oxygen level, solid content level, and nutrient level, which are susceptible to changing to undesired values by a reversible reaction. Specifically, by lowering BOD levels and solid content and increasing or substantially maintaining dissolved oxygen levels in wastewater throughout the various stages, the present teachings effectively transition from one treatment type to another, without suffering from drawbacks of a reversible reaction.

In accordance with one embodiment, the inventive process using system 100 of FIG. 1A may begin when a treatment system 100 receives wastewater for treatment directly from an anaerobic tank (e.g., anaerobic tank 102 of FIG. 1A). Inside anaerobic tank 102, complex organic material is broken down into smaller constituent organic material by anaerobic bacteria under anaerobic conditions. By way of example, inside anaerobic tank 102, a temperature may be a value that is between about 30° C. and 40° C., a pressure that is about 1 atmosphere, and a volume that is between about 10 gallons per minute and about 15,000 gallons per minute. The volume of the tank is completely scalable and may be higher than 15,000 gallons per minute so long as the necessary amount of equipment is used to process a large amount of liquid in parallel.

In the anaerobic tank, the wastewater is treated with microorganisms that carry out anaerobic digestion, causing the release of biogas 128 that is captured atop an anaerobic tank and delivered to a tank (e.g., tank 126 of FIG. 1B), which is preferably a scrubber and is capable of separating methane from the other components of biogas. The wastewater is then immediately advanced for solid removal as one type of treatment. In a preferred embodiment of the present teachings, solid removal is carried out methodically in different steps. It is noteworthy that in this embodiment, not only are solids removed at different steps, but the inventive process is designed to substantially maintain the level of dissolved oxygen in wastewater during these steps to avoid a reversible reaction.

Solid removal preferably begins with removal of relatively large solids from wastewater using a mechanical technique. By way of example, a solids separator such as the one shown in FIG. 1A is preferably used for pressing wastewater containing solids because it also introduces air into the wastewater during the pressing action. As a result, pressing not only removes large solids from wastewater but also maintains the level of dissolved oxygen in wastewater. At this early stage of solid removal, an aerobic process ensures a natural biological degradation and purification process in which bacteria that thrive in oxygen-rich environment break down and digest the organic matter. Maintaining oxygen levels during solid removal ensures that such bacteria do not die off and that level of BOD-contributing solids and solid content in wastewater does not increase. Undesired increase in BOD-contributing solids at this stage would defeat the ultimate purpose of removing the BOD-contributing solids in this step. In other words, during a single treatment step, lowering solid content, lowering BOD level, and substantially maintaining or increasing level of dissolved oxygen in wastewater prevents a reversible reaction that increases BOD, solid content, and/or lowers level of dissolved oxygen in wastewater.

After removing large solids, preferred embodiments of the present teachings focus on the removal of medium-sized particles using small air bubbles. In this treatment step, medium-sized solids are carried by an upward motion of air bubbles and removed as explained previously. As a result, bubbles remove BOD-contributing solids, lower solid content, and introduce oxygen simultaneously to substantially maintain or increase a level of dissolved oxygen in wastewater. The advantages of lowering BOD and solid content, and at the same time substantially maintaining or increasing a level of dissolved oxygen in wastewater realized in the previous step, are also realized in this step.

For removal of finer solids from wastewater, the inventive process in a preferred embodiment moves to a tank, such as SRT 108 as shown in FIG. 1A. This tank also stabilizes the wastewater before removal of organic matter commences. Specifically, the tank is designed to remove fine solid particles using a screen when diffused airflow is used inside the tank. Such air flow provides cleaning action to remove the solid build up on the screen and introduces oxygen into wastewater. The advantages of lowering BOD and solid content in wastewater, and at the same time substantially maintaining or increasing level of dissolved oxygen in wastewater realized in the previous steps, are also realized in this step.

Next, the inventive process preferably moves to removal of organic matter as another type of treatment. In this stage of treatment, preferably in a BCR, such as the one shown in FIG. 1A, microorganisms in the presence of biological chips consume organic matter. The microorganisms release gas containing ammonia and sulfur. Various steps of the present teachings (described below with reference to FIG. 1C) provide a means to clean this gas with recycled wastewater 125. Consumption of organic matter by microorganisms is enhanced by the presence of a blower, which introduces oxygen into wastewater, increasing level of dissolved oxygen in wastewater. With removal of organic matter, wastewater has lower BOD level and solid content and increased level of dissolved oxygen. Microorganisms after consuming a substantial amount of organic material, however, die off and increase both BOD level and solid content. If the dead microorganisms are not timely removed, level of dissolved oxygen in wastewater will drop and a reversible reaction will increase BOD level and solid content in wastewater.

As a result, in the next treatment step, the present teachings offer provisions to remove dead microorganisms from wastewater. To this end, preferably, first anaerobic treatment and then an aerobic treatment is used. It is noteworthy that in preferred embodiments of the present teachings, wastewater at this stage is subjected to anaerobic digestion for a second time. In the anaerobic treatment at this stage, preferably an SRT is sealed off to make sure that all aerobic microorganisms die off. At the same time, using screens inside the SRT, dead microorganisms are removed using screens inside the SRT. This lowers both BOD level and solid content in wastewater. But, before wastewater may advance to the next stage, the present teachings realize that level of dissolved oxygen in wastewater should increase.

In the next step, aerobic treatment is preferably carried out using a DAF tank such as the one shown in FIG. 1A. Diffused airflow inside the DAF tank raises level of dissolved oxygen and removes residual solids. Now, wastewater having lower BOD level and solid content and higher level of dissolved oxygen is ready for the next stage of treatment.

In the next stage, wastewater is treated in algal pond, preferably an HRAP such as the one shown in FIG. 1A, to effectively remove nutrients from wastewater. Nutrient removal from wastewater is carried out by algae, which in the presence of an operating radiation source effectively consumes nutrients. Algae also boost level of dissolved oxygen in wastewater. However, level of dissolved oxygen in wastewater may not be high enough to meet the requirement of discharge to environment.

It is important to recognize that if after anaerobic treatment aerobic treatment did not follow, then wastewater with high concentration of ammonia, as opposed to nitrates or nitrogen, would have entered the HRAP posing a risk of killing algae. Thus, anaerobic treatment followed by aerobic treatment ensures that wastewater is prepared for nutrient removal in the subsequent steps.

In the next treatment steps, dissolved oxygen level in wastewater is raised to allow discharge to environment. Preferably a DAF tank is used to provide diffused air flow for raising level of dissolved oxygen and removing algae and other solids from wastewater. Solid removal lowers BOD level and solid content in wastewater. Then, for removal of finer particles, wastewater is advanced to an SRT, which uses diffused air for removal of solids from and introduction of oxygen to wastewater. Consequently, wastewater has the requisite high level of dissolved oxygen, lower BOD level, and solid content for discharge into environment.

Although wastewater is now ready for discharge into environment, preferred embodiments treat this wastewater in a maturation pond where it is exposed to elements found in the environment. Wastewater matures and is adapted to the natural environment in the maturation pond, from where it is discharged to the environment.

As shown in FIG. 1A, solids removal is carried out at least partially in DAF tank 106 and SRT 108. During such solids removal, however, aerobic bacteria are typically present. As a result, when oxygen is added to these tanks during solids removal, these tanks are not only efficiently removing solids, but are effectively carrying out aerobic digestion on the wastewater well before that wastewater reaches the BCR reactors, where the wastewater further undergoes aerobic digestion.

In accordance with preferred embodiments, the inventive processes on a parallel track treat the gaseous byproducts produced during wastewater treatment. By way of example, biogas (e.g., methane, carbon dioxide, ammonia, hydrogen, and sulfur) resulting from anaerobic digestion is delivered from an anaerobic tank to another tank, which is preferably a scrubber. Before biogas is conveyed to the tank, the tank is filled with water, which is preferably treated water obtained after the conclusion of a wastewater treatment process. Inside the tank, water contacts the biogas. In preferred embodiments of the present teachings, biogas is in the form of tiny micro bubbles when it contacts water. Biogas in bubble form provides a high surface area between the biogas/water interface to allow certain gases in the biogas mixture to dissolve in water. However, as methane does not dissolve in water, it exhausts from the tank. Instead of releasing methane exhaust into the atmosphere, as conventional processes do, the present teachings deliver methane for further processing to an electrical generator located downstream. From inside the tank, a stream of water, which contains certain biogas components dissolved therein, is discharged to a tank for solids removal (e.g., DAF tank 106 of FIG. 1A).

The methane exhaust is further processed (e.g., in system 170 of FIG. 5) to produce electricity and other useful products. Specifically, methane gas is delivered to an electrical generator, which converts methane to electricity and produces other byproduct gases (e.g., at least one of CO₂, SO_(x), and NO_(x)). These gaseous byproducts are next conveyed to a tank, preferably a scrubber, where they are treated substantially similarly to the treatment of biogas as a byproduct (i.e., tiny micro bubbles of the gaseous mixture are conveyed through water to dissolve those components of the gaseous mixture which dissolve in water). Preferably, treated water is used to process the byproduct gas. Residual gas not dissolved in water is recirculated back to the tank for further processing i.e., multiple passes may be made through the tank to dissolve the residual gases in water. Water effluent that includes the dissolved gases is conveyed to an algal pond (e.g., HRAP 118 of FIG. 1A) to promote algae growth. With regard to the energy produced by the electrical generator, the amount of energy is significant. By way of example, for a farm that raises dairy cattle, an electrical generator produces between about 1 and about 5 kilowatts of electricity per day per animal.

Processing of wastewater by aerobic digestion also produces byproducts, which are treated according to the preferred embodiments of novel systems and methods of the present teachings. In accordance with one preferred embodiment, the inventive processes may begin when byproduct gas is received into a tank, preferably a scrubber, after wastewater has undergone aerobic digestion (e.g., in BCRs 110 and 112). Byproduct gas (e.g., shown denoted by reference numeral 142 of FIG. 1C) of aerobic digestion includes at least one of ammonia gas and sulfur gas. Before the byproduct gas is received, however, the tank is filled with water, which is preferably treated wastewater. In preferred embodiments, byproduct gas processed according to the present teachings is introduced in bubble form. A certain amount that is soluble of certain components of the byproduct gas dissolve in water and the remaining, undissolved amounts or components, such as residual ammonia gas or residual sulfur gas, are recycled back to the tank further processing (i.e., for further attempts to dissolve the residual ammonia gas and sulfur gas in water in subsequent contact cycles in the tank). The resulting effluent stream enriched with the soluble byproduct gas components is discharged from the tank and processed depending on the concentration of aqueous ammonia and sulfur in the water stream.

Using an ammonia concentration sensor, the concentration of ammonia in the wastewater is determined. If the effluent contains ammonia in a concentration that is greater or equal to a predetermined concentration value, then the ammonia is typically sent back to the BCR reactor, from where the byproduct gas had originated. In this BCR, the residual ammonia gas undergoes further processing so that it is reduced to simpler molecular forms, such as nitrates, nitrites, or nitrogen, which are useful for algae growth (e.g., in HRAP 118 of FIG. 1A). If, however, the concentration of ammonia is sufficiently low, i.e., below the predetermined concentration value, then the effluent stream is considered to have simpler forms of nitrogen which are useful for algae growth. Accordingly, effluent streams with such low concentrations of ammonia are advanced to an algal pond (e.g., in HRAP 118 of FIG. 1A).

In other preferred embodiments of the present teachings, the concentration of sulfur is similarly discerned. If the sulfur concentration sensor detects the concentration of sulfur gas to be greater than or equal to a predetermined concentration value, then the effluent stream is returned back to the BCR reactor, from where the byproduct gas had originated. In this BCR, the residual sulfur gas undergoes further processing so that it is consumed if not in the first pass back to the BCR, then in the subsequent ones. Alternatively, if the sulfur concentration detects the concentration of sulfur gas to be less than the predetermined concentration value, then the effluent stream advances to the algal pond. In light of the above disclosure, those skilled in the art will recognize that in preferred embodiments of the present teachings, the effluent stream of the tank (e.g., a scrubber) are only advanced to an algal pond when both concentration of aqueous ammonia and sulfur gas are below their respective predetermined concentration values. However, compared to ammonia, sulfur is known to dissipate relatively quickly and, therefore, in preferred embodiments of the present teachings, only the concentration of ammonia in the effluent stream is monitored as described above.

FIG. 6 shows a system 600, according to one preferred present arrangement, for converting solid byproducts of wastewater treatment into a plant life enhancing product, e.g., fertilizer, biocide, pesticide, and/or agricultural feed. System 600 includes an anaerobic feed tank 602, a solids separator 604, a DAF tank 606, an SRT #1 608, a BCR #1 610, a BCR #2 612, an aerobic sludge digester 614, an SRT #2 616, an HRAP 618, and an SRT #3 620, each of which is substantially similar to their counterparts, anaerobic feed tank 102, solids separator 104, DAF 106, SRT #1 108, BCR #1 110, BCR #2 112, aerobic sludge digester 114, SRT #2 116, HRAP 118, and SRT #3 120, respectively, in system 100 of FIG. 1A.

System 600 further includes an intermediate blender 660, that receives and blends different types of solid byproducts of wastewater treatment, i.e., anaerobically activated coarse solids 650, anaerobically activated medium-sized solids 624, and/or anaerobically activated fine solids 652, produced from solids separator 604, DAF tank 606, and SRT #1 608, respectively, to form an anaerobically activated organic residue 662. Preferably, these various-sized solids primarily include fibrous, cellular material (e.g., lignin, cellulose, hemicellulose) that is broken down in the above-mentioned components.

System 600 further includes a blender 664 that receives and mixes anaerobically activated organic residue 662 from blender 664 with one or more of other solid byproducts of wastewater treatment, i.e., aerobically activated organic residue 627, dead microorganisms 654, algae-enriched slurry 656, and/or algae 658, from aerobic sludge digester 614, SRT #2 616, HRAP 618, and SRT #3, respectively, to form a slurry 666. The present arrangement also optionally includes a dryer 668 capable of drying slurry 666, and a pelletizer 670 capable of pelletizing the dried product received from dryer 668.

Anaerobic feed tank 602 is designed to receive wastewater, which includes agricultural residue (e.g., biomass and manure), and treats the wastewater under anaerobic conditions. Inside anaerobic feed tank 602, among other things, complex organic material from agricultural residue is digested into smaller constituent organic material by anaerobic bacteria. Anaerobic feed tank 602 then delivers the resulting anaerobically activated slurry 632 to solids separator 604 for further treatment.

Solids separator 604 separates anaerobically activated coarse solids 650 from anaerobically activated slurry 632, using mechanical techniques, to form an anaerobically activated slurry depleted of coarse solids 634. Anaerobically activated coarse solids 650 have an average particle size that is greater than about 150 μm. As shown in FIG. 6, once separated from treated wastewater, anaerobically activated coarse solids 650 are delivered to intermediate blender 660 for blending with other types of solid byproducts. Also as shown in FIG. 6, anaerobically activated slurry depleted of coarse solids 634 is then delivered to DAF tank 606 for further treatment.

DAF tank 606 separates anaerobically activated medium-sized solids 624 from anaerobically activated slurry depleted of coarse solids 634 to form an anaerobically activated slurry depleted of medium-sized solids 636. To facilitate their removal, anaerobically activated medium-sized solids 624 are carried by an upward motion of air bubbles introduced into DAF tank 606. DAF tank 606 removes medium-sized solids from wastewater, which have an average particle size that ranges from about 25 μm to about 150 μm. According to FIG. 6, separated, anaerobically activated medium-sized solids 624 are delivered to intermediate blender 660 for blending with other types of solid byproducts. Also, as shown in FIG. 6, anaerobically activated slurry depleted of medium-sized solids 636 is then delivered to SRT #1 608 for further treatment.

SRT #1 608 separates anaerobically activated fine solids 652 from anaerobically activated slurry depleted of medium-sized solids 636 to form anaerobically activated slurry depleted of solids 638. Removal of anaerobically activated fine solids 652 is facilitated by use of a screen when diffused air flow is introduced inside the tank. SRT #1 601 removes solids that have an average particle size that is less than about 25 μm. According to FIG. 6, anaerobically activated fine solids 652 are delivered to intermediate blender 660 for blending with other types of solid byproduct. Also, as shown in FIG. 6, the resulting anaerobically activated slurry depleted of solids 638 is then delivered to BCR #1 610 for further treatment.

Intermediate blender 660 receives and blends one or more of anaerobically activated coarse solids 650, anaerobically activated medium-sized solids 624, and anaerobically activated fine solids 652, to form anaerobically activated organic residue 662. Preferably, intermediate blender 660 is designed to blend relatively fibrous solid byproducts of wastewater treatment (e.g., lignin, cellulose, and hemicellulose). As shown in the embodiment of FIG. 6, intermediate blender 660 delivers anaerobically activated organic residue 662 to blender 664 for blending with other solid byproducts of wastewater treatment. In alternate embodiments of the present arrangement, however, a single blender is configured to blend all solid byproducts of wastewater treatment.

BCR #1 610 treats organic matter from anaerobically activated slurry depleted of solids 638, which are typically enriched with nutrients, by aerobic digestion. Preferably, anaerobically activated slurry depleted of solids 638 are treated with at least one type of microorganism, which consumes organic matter. In one preferred embodiment of the present arrangement, the resulting wastewater slurry 640 treated in BCR #1 610 is delivered to BCR #2 612 for further treatment with one or more microorganisms that preferably consume organic matter that is particularly difficult to remove.

The wastewater slurry 642 resulting from treatment in BCR #2 is delivered to aerobic sludge digester 614 for further treatment under aerobic conditions with one or more microorganisms that are known to consume solid sludge, i.e., accumulated organic matter, producing aerobically activated organic residue 627. Preferably, the microorganisms include at least one microorganism that converts ammonia to nitrites and at least one microorganism that converts nitrites to nitrates.

Aerobically activated organic residue 627 is separated from treated wastewater slurry 642, producing aerobically activated slurry 644, which is in a nutrient-enriched state. As shown in FIG. 6, aerobically activated organic residue 627 is then delivered to blender 664 for blending with other solid byproducts of wastewater treatment. Also as shown in FIG. 6, aerobically activated slurry 644 is then delivered to SRT #2 616 for further treatment.

Though the embodiment of FIG. 6 shows two BCRs and one aerobic sludge digester, alternate embodiments of the present arrangement include any number of BCRs and aerobic sludge digesters. Likewise, other embodiments of the present arrangement include no BCRs or no aerobic sludge digesters.

SRT #2 616 is sealed off to create anaerobic conditions during treatment of aerobically activated slurry 644, which kills substantially all of the aerobic microorganisms utilized in BCR #1 610, BCR #2 612, and aerobic sludge digester 614. Dead microorganisms 654 are then removed, preferably using screens inside SRT #2 616. As shown in FIG. 6, dead microorganisms 654 are next delivered to blender 664 for blending with other solid byproducts of wastewater treatment. Also as shown in FIG. 6, the resulting nutrient-enriched slurry 646 is delivered to HRAP 618 for further treatment. In preferred embodiments of the present teachings, however, nutrient-enriched slurry 646 is first delivered to DAF tank 606 for further aerobic treatment, as described above with reference to FIG. 1A, and then delivered to HRAP 618 for further treatment.

In HRAP 618, algae-enriched slurry 656 is separated from nutrient-enriched slurry 646 to form a nutrient-depleted slurry 648. Algae-enriched slurry 656 is delivered to blender 664 for blending with other solid waste products of wastewater treatment. In certain embodiments of the present arrangement, nutrient-depleted slurry 620 is delivered to SRT #3 620 for further treatment. In preferred embodiments, however, nutrient-depleted slurry 620 if first delivered to DAF tank 606 for further aerobic treatment, as described above with reference to FIG. 1A, and then delivered to SRT #3 620 for further treatment.

In SRT No. 3 620, algae 658 are separated from nutrient-depleted slurry 648. Algae 658 are then delivered to blender 664 for blending with other solid waste products of wastewater treatment. Algae 658, which are rich in nutrients (e.g., nitrogen, phosphorous, and potassium), provides nutrients for use in fertilizer, biocide, pesticide, and/or agricultural feed.

Blender 664 is any blender capable of blending solid waste products of wastewater treatment. Preferably, blender 664 is designed to blend relatively small products of wastewater treatment (e.g., anaerobically activated organic residue 662, aerobically activated organic residue 627, dead bacteria 654, algae-enriched slurry 656, and algae 658) to produce slurry 666. Though the embodiment of FIG. 6 includes intermediate blender 660 and blender 664, alternate embodiments of the present arrangement include one blender that is configured to blend all solid byproducts of wastewater treatment. Regardless of whether a single or multiple blenders are used, the present teachings contemplate the use of an external amendment that provides additional amounts of a desired material (e.g., sulfur and nitrogen) so that a predetermined concentration of the desired material is reached in the plant life enhancing composition. To this end, FIG. 6 shows that, in one embodiment of the present teachings, an external amendment 674 is connected to intermediate blender 660 via a connection 676 and is also connected to a blender 664 via a connection 678. Although it is not necessary to include the external amendment feature and its associated connections, in those instances where the concentration of a desired material needs to be supplemented in the plant life enhancing composition, external amendment 674 and at least one of the associated connections represent a preferred embodiment of the present teachings.

Slurry 666 is comprised of one or more of anaerobically activated organic residue 662, aerobically activated organic 627, dead bacteria 654, algae-enriched slurry 656, and algae 658. Slurry 666 may be used to produce a plant life enhancing composition, e.g., fertilizer, pesticide, biocide, and/or agricultural feed, though in alternate embodiments of the present arrangement, slurry 666 may optionally be delivered to dryer 668 for drying.

Dryer 668 is any dryer capable of drying slurry 666. The dried product resulting from dryer 668 may be used as fertilizer, pesticide, biocide, and/or agricultural feed. Optionally, however, the dried product may instead be delivered to pelletizer 670 for pelletizing.

Pelletizer 670 is any pelletizer capable of pelletizing the dried product of dryer 668. In one preferred arrangement, the pellets resulting from pelletizer are used as a plant life enhancing composition, e.g., fertilizer, pesticide, biocide, and/or agricultural feed.

FIG. 7 shows a process 700, according to one preferred arrangement, for converting solid byproducts of wastewater treatment into a plant life enhancing product, e.g., fertilizer, biocide, pesticide, and/or agricultural feed. Process 700 begins with a first step 702, which includes anaerobically digesting agricultural residue to produce anaerobically activated organic residue and ammonia-enriched water. According to one preferred arrangement, anaerobically digesting agricultural residue to produce an anaerobically activated organic residue and an ammonia-enriched water is carried out using a series of components (e.g., anaerobic feed tank 602, solids separator 604, DAF tank 606, and SRT #1 608 of FIG. 6) that treat organic residue under anaerobic conditions and remove various-sized solid byproducts of wastewater treatment (e.g., anaerobically activated coarse solids 650, anaerobically activated medium-sized solids 624, and/or anaerobically activated fine solids 652 of FIG. 6) from wastewater. The resulting wastewater is ammonia-enriched and delivered for further treatment.

Though not shown in FIG. 7, prior to step 704, anaerobically activated organic waste, which is comprised of one or more of coarse, medium-sized, and fine solids, is preferably delivered to an intermediate blender (e.g., intermediate blender 660 of FIG. 6) for blending. The present teachings recognize that the ratio of coarse, medium-sized, and fine solids in anaerobically activated organic waste delivered to the intermediate blender may be adjusted so as to optimize formulations for a plant life enhancing product, e.g., fertilizer, biocide, pesticide, and/or agricultural feed. In doing so, the present arrangement recognizes that coarse solids produced by a solids separator (e.g., solids separator 604 of FIG. 6) are relatively less broken down than medium-sized solids produced by a DAF tank (e.g., DAF tank 606 of FIG. 6). Likewise, medium-sized solids are relatively less broken down than fine solids produced by an SRT (e.g., SRT #1 608 of FIG. 6). It is noteworthy that as these solids are progressively broken down, nitrogen, in the form of ammonia, is made progressively more bioavailable. Accordingly, the release of nitrogen in plant life enhancing compositions, such as fertilizer, pesticide, and/or biocide is optimized by adjusting the ratio of coarse, medium-sized, and fine solids in anaerobically activated organic waste. By way of example, a fast-acting fertilizer, i.e., where nitrogen in the form of ammonia is readily available for uptake, may be comprised of relatively more fine solids, which contain more bioavailable nitrogen than coarse and medium-sized solids. Likewise, a slow-acting fertilizer may be comprised of relatively more coarse solids, which contain nitrogen that is less bioavailable and therefore released more slowly, over a longer period of time.

Next, a step 704 includes aerobically digesting the ammonia-enriched water to produce aerobically activated organic residue. Preferably, aerobic digestion is carried out in a series of components (e.g., BCR #1 610, BCR #2 612, and aerobic sludge digester 614 of FIG. 6) that facilitate removal of aerobically activated organic residue.

Though not shown in FIG. 7, ammonia-enriched water is preferably further treated in a series of components, including an SRT (e.g., SRT #2 616 of FIG. 6), an HRAP (e.g., HRAP 618 of FIG. 6), and another SRT (e.g., SRT #3 620), which facilitate removal of other solid byproducts of wastewater treatment, including dead microorganisms, algae-enriched slurry, and algae, respectively.

Next, a step 706 includes blending the anaerobically activated organic residue with the aerobically activated organic residue to produce fertilizer. Though not shown in FIG. 7, other byproducts of wastewater treatment (e.g., dead microorganisms, algae-enriched slurry, and algae) are preferably also blended with anaerobically activated organic residue to produce fertilizer. In preferred embodiments of the present arrangement, however, the blended product is a precursor to a plant life enhancing composition that is delivered to a dryer and a pelletizer to ultimately produce the plant life enhancing composition.

In a similar manner to that described above with reference to step 702, the ratio of each solid waste component blended in step 706 (e.g., anaerobically activated organic residue, dead microorganisms, algae-enriched slurry, and algae) may be delivered to the blender in ratios that produce optimized formulations of fertilizer.

In one embodiment of the present teachings, a plant life enhancing composition includes an effective amount of a bioavailable component that is available for immediate absorption by a plant and an effective amount of a precursor component, which has a more complex molecular structure than the bioavailable component. Over a period of time the precursor component transforms into the bioavailable component. In this embodiment, an effective amount of a catalyst is also provided. The catalyst facilitates transformation of the precursor component (i.e., more complex molecules) to the bioavailable component (i.e., less complex molecules).

The period of time to transform the precursor component to a bioavailable component may vary depending on various factors, such as the temperature at which the plant enhancing composition is placed, amount of activating agent, such as water, and the complexity of the precursor component. In one preferred embodiment of the present teachings, duration is a period of time that ranges from about one day to about six months.

An effective amount of the catalyst may be a value that ranges from about. 0.01% (by weight of the fertilizer) to about 2% (by weight of the fertilizer). The catalyst may include an enzyme. In the presence of the enzyme, the precursor component is transformed to the bioavailable component at a rate that may be between about 3 times and about 4 times faster than a rate of transforming the precursor component to the bioavailable component in absence of the catalyst. In one embodiment of the present teachings, the enzyme includes at least one member chosen from a group comprising β-glucosidase, fluorescein diacetate hydrolysis, amidase, urease, phosphatase, sulfatase, endoglumayase, cellobiohydrolase, β-glucosidase cellobiohydrolase, endoxylanase, endomannanase, β-glycosidases, esterases, endochitinase, N-acetlyglucosaminidase, α-glucosidase, Mn-peroxidase, lignin peroxidase, laccase, phenoloxidase, proteases, aminopeptidases, urease, phosphomonoesterase, phospohodiesterase and arylsulfatase.

In the plant life enhancing composition, the bioavailable component includes an effective amount of micronutrient and/or an effective amount of macronutrient to enhance plant growth. The effective amount of each of the micronutrient and the macronutrient is a value that may range from about 0.1% (by weight of the bioavailable component) to about 6% (by weight of the bioavailable component). The micronutrient preferably includes at least one member selected from a group comprising boron, cobalt, chromium, copper, fluorine, iodine, molybdenum, selenium, zinc, chlorine, iron, manganese, zinc and nickel. The macronutrient preferably includes at least one member selected from a group comprising nitrogen, potassium, calcium, magnesium, phosphorous, carbon and sulfur.

The precursor component preferably includes an effective amount of non-bioavailable forms of a member chosen from a group comprising boron, cobalt, chromium, copper, fluorine, iodine, molybdenum, selenium, zinc, chlorine, iron, manganese, zinc, nickel, nitrogen, potassium, calcium, magnesium, phosphorous, carbon and sulfur. The effective amount of the precursor component may be a value that ranges from about 0.01% (by weight of the plant life enhancing composition) to about 10% (by weight of the plant life enhancing composition). In other aspects, the plant life enhancing composition of the present teachings include an effective amount of a dormant component, which, in turn, may include any one of aerobically activated organic residue 627, dead bacteria 654, algae-enriched slurry 656 and algae 658). In this aspect, an effective amount of a decomposed dormant component may also be present. The decomposed dormant component includes an output of anaerobic digestion. By way of example, decomposed dormant component includes anaerobically activated fine solids which may comprise any one of activated coarse solids 650, anaerobically activated medium-sized solids 624, and anaerobically activated fine solids 652.

The resulting plant life enhancing composition, as discussed above, in some instances may not have a sufficient amount of a desired material. To this end, the plant life enhancing composition may be admixed with an effective amount of an amendment to provide a predetermined amount of one more desired materials that are inorganic or organic in nature. Examples of one or more of the desired materials may include sulfur and/or nitrogen.

In another embodiment, the present teachings provide a plant life enhancing composition that includes effective amounts of each of a dormant component, a decomposed dormant component and a catalyst. The dormant component includes an output of aerobic digestion (e.g., aerobically activated organic residue) and the decomposed dormant component includes an output of anaerobic digestion (e.g., anaerobically activated organic residue), as discussed above. The catalyst facilitates transformation of the dormant component to the decomposed dormant component. Further, the catalyst may also transform the decomposed dormant component to a bioavailable component in the plant life enhancing composition of the present teachings. Effective amount of each of the dormant and the decomposed dormant component may be a value that ranges from about 0.01% (by weight of the plant life enhancing component) to about 10% (by weight of the plant life enhancing component). The effective amount of the catalyst is a value that may range from about 0.01% (by weight of the plant life enhancing component) to about 2% (by weight of the plant life enhancing component) and in presence of the catalyst. Further, the dormant component is transformed to the decomposed dormant component at a rate that may be between about 3 times and about 4 times faster than a rate of transforming the dormant component to the decomposed dormant component in absence of the catalyst. In one aspect, the present teachings propose that enzymes be used to serve as catalysts, as they promote plant growth and effectively activate bacteria, which facilitates transforming the dormant component to the decomposed dormant component discussed above.

Although illustrative embodiments of the present teachings have been shown and described, other modifications, changes, and substitutions are intended. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims. 

The invention claimed is:
 1. A method for producing a plant life enhancing product, said method comprising; anaerobically digesting agricultural residue to produce an anaerobically activated organic residue and an ammonia-enriched water; separating said anaerobically activated organic residue from said ammonia-enriched water to produce separated anaerobically activated organic residue and anaerobically-treated ammonia-enriched water; aerobically digesting said anaerobically-treated ammonia-enriched water to produce an aerobically activated organic residue; and blending said separated anaerobically activated organic residue with said aerobically activated organic residue to produce said plant life enhancing product.
 2. The method of claim 1, wherein said separated anaerobically activated organic residue is blended following said anaerobically digesting agricultural residue.
 3. The method of claim 1, further comprising drying said plant life enhancing product to form a dried plant life enhancing product.
 4. The method of claim 3, further comprising pelletizing said dried plant life enhancing product.
 5. The method of claim 1, wherein said plant life enhancing product is used as at least one member selected from a group comprising biocide, pesticide, and agricultural feed product.
 6. The method of claim 1, further comprising removing solids from anaerobically activated organic residue.
 7. The method of claim 1, wherein said aerobically digesting produces aerobically-treated water, and said method further comprising separating said aerobically activated organic residue from said aerobically-treated water.
 8. The method of claim 7, wherein separating said aerobically activated organic residue from said aerobically-treated water produces said separated aerobically activated organic residue, and wherein said blending includes blending said separated anaerobically activated organic residue with said separated aerobically activated organic residue to produce said plant life enhancing product. 